Exterior polymer-based brick building material

ABSTRACT

A simulated brick includes a polymeric core member ( 20 ), a mesh layer ( 30 ) adhered to the core member, a basecoat layer ( 43 ) covering an entirety of the mesh layer, and a finish layer ( 46 ) covering an entirety of the basecoat layer. The core member, the mesh layer, the basecoat layer, and the finish layer together define a brick profile portion ( 11 ) having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion ( 12 ) extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface ( 16 ) extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion.

CROSS-REFERENCE TO RELATED APPLICATION

This application is the U.S. national stage entry of PCT/US2016/049818,filed Sep. 1, 2016, which claims priority to and all benefit of U.S.Provisional Patent Application Ser. No. 62/212,884, filed on Sep. 1,2015, entitled EXTERIOR POLYMER-BASED BRICK BUILDING MATERIAL, theentire disclosures of which are fully incorporated herein by reference.

BACKGROUND

The use of common clay brick as a finish for all types of buildings isvery popular and provides unique aesthetics, but such brick finishes arerelatively expensive and commonly offer poor insulation. Thin brickcladding, installed over sheathing, concrete, insulation boards, andmasonry substrates has been available as an alternative, but such wallcladding systems are often deficient in fire resistant properties andease of installation.

SUMMARY

The present disclosure is directed to polymer-based building products,particularly polymer-based exterior wall cladding and exterior wallcladding systems, and related methods for preparing the exterior wallcladding and exterior wall cladding systems.

Accordingly, in an exemplary embodiment, a simulated brick includes apolymeric core member, a mesh layer adhered to the core member, abasecoat layer covering an entirety of the mesh layer, and a finishlayer covering an entirety of the basecoat layer. The core member, themesh layer, the basecoat layer, and the finish layer together define abrick profile portion having first and second lateral sides extending toa planar outer surface to define a first thickness, and an offsetportion extending from the first lateral side of the brick profileportion to a lateral end surface and having an outer surface defining asecond thickness smaller than the first thickness, the brick profileportion and the offset portion together defining a planar rectangularbase surface extending from the second lateral side of the brick profileportion to the lateral end surface of the offset portion.

In another exemplary embodiment, a method of manufacturing a simulatedbrick is contemplated. In an exemplary method, a polymeric core memberis formed, the core member including a brick profile portion havingfirst and second lateral sides extending to a planar outer surface todefine a first thickness, and an offset portion extending from the firstlateral side of the brick profile portion to a lateral end surface andhaving an outer surface defining a second thickness smaller than thefirst thickness, the brick profile portion and the offset portiontogether defining a planar rectangular base surface extending from thesecond lateral side of the brick profile portion to the lateral endsurface of the offset portion. A mesh layer is adhered to the first andsecond lateral sides and the outer surface of the brick profile portionand to the lateral end surface and the outer surface of the offsetportion. A basecoat layer is deposited onto an entirety of the meshlayer. A finish layer is deposited onto an entirety of the basecoatlayer.

In another exemplary embodiment, a method of applying simulated bricksto a wall surface is contemplated. In an exemplary method, at leastfirst and second simulated bricks are provided, with each including abrick profile portion having first and second lateral sides extending toa planar outer surface to define a first thickness, and an offsetportion extending from the first lateral side of the brick profileportion to a lateral end surface and having an outer surface defining asecond thickness smaller than the first thickness, the brick profileportion and the offset portion together defining a planar rectangularbase surface extending from the second lateral side of the brick profileportion to the lateral end surface of the offset portion. An adhesivelayer is applied to the wall surface. The base surface of the firstsimulated brick is adhered to the adhesive layer, and the base surfaceof the second simulated brick is adhered to the adhesive layer such thatat least a portion of the lateral end surface of the offset portion ofthe second simulated brick abuts the second lateral side of the brickprofile portion of the first simulated brick. A grout material isapplied to the outer surface of the offset portion of the secondsimulated brick.

In another exemplary embodiment, a wall system includes a wall substratehaving a substantially planar exterior surface, and at least first andsecond simulated bricks. The first and second simulated bricks eachinclude a brick profile portion having first and second lateral sidesextending to a planar outer surface to define a first thickness, and anoffset portion extending from the first lateral side of the brickprofile portion to a lateral end surface and having an outer surfacedefining a second thickness smaller than the first thickness, the brickprofile portion and the offset portion together defining a planarrectangular base surface extending from the second lateral side of thebrick profile portion to the lateral end surface of the offset portion.The planar rectangular base surfaces of the first and second simulatedbricks are adhered to the exterior surface of the wall substrate suchthat at least a portion of the lateral end surface of the offset portionof the second simulated brick abuts the second lateral side of the brickprofile portion of the first simulated brick. A grout material isadhered to the outer surface of the offset portion of the secondsimulated brick.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an upper perspective view of an exemplary simulated brickwall cladding component according to the present disclosure;

FIG. 2 shows an upper perspective cut-away cross-sectional view of thesimulated brick wall cladding component of FIG. 1;

FIG. 3 shows an end view of an exemplary embodiment of a simulated brickwall cladding component; and

FIG. 4 shows a perspective view of cut-away exterior wall systemincluding an array of simulated brick wall cladding components securedto an exterior wall substrate.

DETAILED DESCRIPTION

The present disclosure is directed to insulative wall cladding buildingproducts, particularly polymer-based simulated bricks, and relatedmethods for preparing and installing the building products. In certainexemplary embodiments, a polymer-based building product includes apolymer core member at least partially covered with a reinforcing meshmaterial, such as a fiberglass mesh material. The reinforcing meshmaterial is at least partially coated with or at least partiallyembedded in a basecoat layer, such as a polymer-modified cementitiousbasecoat, and the basecoat layer is at least partially covered by anoutermost finish layer, to provide a desired color and texture for thewall cladding. In one such exemplary embodiment, the textured finishlayer gives the exterior wall cladding the appearance of a conventionalclay brick.

FIGS. 1 and 2 illustrate an exemplary simulated brick 10 including apolymeric core member 20, a mesh layer 30 adhered to the core member 20,and a coating 40 covering the mesh layer 30. In some embodiments, thecoating may include a single layer providing protection for the coremember, a barrier to fire propagation, exterior surface durability, anddesired exterior aesthetic characteristics (e.g., color, texture). Inother embodiments, as shown, the coating 40 may include an inner,basecoat layer 43 directly deposited (e.g., by extrusion coating) ontothe mesh layer 30 to cover the mesh layer and to provide strength andfire barrier properties, and a finish layer 46 deposited (e.g., byextrusion coating) onto the basecoat layer 43 to provide desired surfacedurability and exterior aesthetic properties. In still otherembodiments, additional coating layers may be provided.

The mesh layer 30, basecoat layer 43, and the finish layer 46 maytogether form a relatively thin (e.g., about ⅛ inch thick) laminate 19defining the lateral (or side) surfaces 13 a, 13 b, 13 c and outer (ortop) surfaces 14 a, 14 b of the simulated brick 10. As shown, the endsurfaces 15 a, 15 b of the core member 20 may remain exposed oruncovered by the laminate 19, allowing for production of the simulatedbricks by forming an elongated laminated core that is cut into multiplebrick-sized wall cladding components. A base (or bottom) surface 16 ofthe core member 20 may also be exposed or uncovered by the laminate 19,for example, to facilitate adhesion of the simulated brick 10 to a wallsurface.

The core member material may be selected to provide desired insulationproperties. Exemplary materials include polystyrene foams such asexpanded polystyrene (“EPS”) or extruded polystyrene (“XPS”) or othersimilar insulation materials, including, for example, polyisocyanurate,polyurethane, and foam glass. In certain embodiments, the core is apolymer material having a density of about 0.5 to about 5 pcf, or about1 to about 2 pcf, or about 1.5 pcf. In an exemplary embodiment, the coreis an XPS having a density of 1.5 pcf. In accordance with certainexemplary embodiments, the core is an XPS meeting ASTM C578. Theinsulative polymer core member may provide an effective R-value betweenabout 2 and about 8 h·° F.·ft²·in/BTU. In an exemplary embodiment, anXPS core member has an R-value of about 5 h·° F.·ft²·in/BTU.

The mesh layer 30 may include a variety of reinforcing, strengthening,and/or fire resistant mesh materials, such as, for example, a fiberglassor polymer strand material. Non-limiting examples of suitable polymermesh materials include polyester, polypropylene, aramid, and carbon. Thereinforcing mesh may be constructed using an open weave. In certainembodiments, the reinforcing mesh material includes or is coated with analkali resistant material. In certain embodiments, the mesh layer 30 isprovided with an adhesive on one side so it can be applied directly tothe surface of the core member 20 to maintain its position until thebasecoat layer 43 is deposited over the mesh layer. The alkaliresistance improves compatibility of the reinforcing mesh material withcement-based materials, such as cement-based mortars, grouts, basecoatlayer, and the like used in accordance with the present disclosure. Inone such exemplary embodiment, the reinforcing mesh material comprisesan about 3.6 lbs/yd² weight, open weave of fiberglass strands includingalkali resistant glass and/or glass fibers coated with an alkaliresistant material. In certain embodiments, the reinforcing meshmaterial comprises a fire resistant or non-combustible material, such ascertain types of fiberglass and/or certain fiberglass or polymer strandscoated with a fire resistant size composition. The fire resistant meshmaterial may be selected to produce, in combination with the othersimulated brick materials, a wall cladding product suitable to meet oneor more applicable non-combustible, fire resistant, and/or fire proofstandards, including, for example, NFPA 285, NFPA 268, ASTM E84, andASTM E119. In one such example, the mesh material has a melting point ofapproximately 2000° F.

The basecoat layer 43 may include any of a variety of suitable materialscompatible with, and adherent to, the core 20, mesh 30, and texturedfinish layer 46, such as, for example, a polymer modified cementitiousmortar material. In an exemplary embodiment, the basecoat layercomprises a Type N or S mortar modified with a suitable amount ofacrylic polymer to provide improved adhesion, flexibility andworkability. One such polymer modified mortar material includes Portlandcement, silica sands, styrene acrylic based polymers and othernon-combustible fillers. As shown, the basecoat layer 43 may cover anentirety of the mesh layer 30.

The textured finish layer 46 may include any of a variety of suitablematerials compatible with, and adherent to, the basecoat layer 43 andmortar/grout material used with the simulated bricks (described below),and that provides the desired durability, texture, and appearance, suchas that of a clay brick. Exemplary materials include acrylic, styreneacrylic, veova, or vinyl acrylic acetate. The textured surface layer maybe suited to weather a variety of external environmental conditions,such as damaging effects caused by the sun, rain, cold, humidity, etc.As shown, the finish layer 46 may cover an entirety of the basecoatlayer 43.

In accordance with certain embodiments, the exterior wall cladding(e.g., simulated bricks) may be applied to any common exterior wallsurface, including, plywood, oriented strand board, glass mat gypsumsheathing, cement board sheathing, ICF's, exterior insulation and finishsystem (“EIFS”) basecoat, concrete, and masonry. Typically, square-edgedinsulation bricks (which are not in accordance with the presentdisclosure) are applied to an uncoated expanded polystyrene core memberthat has built-in projecting strips or offsets, thereby allowing thesquared-edged brick to maintain its position on the wall withoutsliding. Square-edged insulation bricks applied to other surfacesrequire the use of tile spacers or metal pans and clips to allow thebricks to stay in position without sliding and also to keep a consistentgrout joint.

According to one aspect of the present application, a simulated brickwall cladding component may be provided with a brick profile portion andat least one offset portion extend from at least one lateral side of thebrick profile portion to abut at least a portion of a brick profileportion of an adjacent simulated brick when the simulated bricks aresecured to a wall surface. The offset portion may facilitateinstallation of a multiple row array of the simulated bricks, byproviding for consistent, uniform spacing between the brick profileportions of adjacent rows of simulated bricks, preventing misalignmentdue to slippage without the use of spacer tiles, clips, or metal pans,as commonly used in the installation of conventional “thin brick” wallcladding. Additionally, these offset portions may provide additionalinsulation for the mortar joint spaces between the simulated bricks.

To form a simulated brick having a lateral offset portion, as shown inFIGS. 1 and 2, the core member 20 may be provided with a brick profileportion 11, generally in the shape of a thin brick (e.g., about 7⅝inches long, about 2¼ inches wide, and about 1 inch thick, or about 7⅝inches long, about 2⅝ inches wide, and about 1⅛ inches thick, or about11⅝ inches long, about 4 inches wide, and about 1⅛ inches thick). Theexemplary brick profile portion includes first and second lateral sides13 a, 13 b extending to a planar outer surface to define a uniformthickness, and a thinner lip or offset portion 12 extending laterallyfrom the first lateral side 13 a of the brick profile portion 11 to alateral end surface 13 c of the offset portion. The brick profileportion 11 and the offset portion 12 together define a planarrectangular base surface 16 extending from the second lateral side 13 bof the brick profile portion to the lateral end surface 13 c of theoffset portion 12. As shown, the first and second lateral sides 13 a, 13b, the lateral end surface 13 c, and the outer surfaces 14 a, 14 b maybe defined by the finish layer 46, and the base surface 16 may bedefined by the core member 20.

In the exemplary embodiment, the offset portion 12 extends a distancecorresponding to a desired width of a mortar joint to be applied betweenadjacent rows of simulated bricks 10 (e.g., about ⅜ inches), such thatabutment of the thinner offset portion 12 with the brick profile portionof an adjacent brick defines a gap sized to be filled with a mortarjoint of the desired width. In other embodiments (not shown), asimulated brick may be provided with smaller offset portions (e.g.,about 3/16 inches) extending from both lateral sides of the brickprofile portion, such that abutment of the offset portions of adjacentrows of simulated bricks define a gap sized to be filled with a mortarjoint of the desired width. In still other embodiments (not shown), asimulated brick may be provided with an offset portion extending fromeither or both of the longitudinal ends of the simulated brick, suchthat abutment of adjacent simulated bricks in a row defines a gap sizedbetween adjacent longitudinal ends of the brick profile portions, to befilled with a mortar joint of the desired width.

The offset portion may be provided in a wide variety of suitablethicknesses, thick enough to function as a rigid spacer, and thin enoughto provide sufficient space for grout material to provide the appearanceof conventional brick masonry. The ratio of the thickness of the offsetportion to the thickness of the brick profile portion may, for example,be between 5% and 70%, or between 35% and 60%. In one example, theoffset portion thickness is about ⅝ inches.

The offset portion 12 of the simulated brick 10 may also provideadditional insulation for the wall to which the simulated bricks aresecured, as the core member material may have a significantly greaterR-value than the mortar/grout component material (e.g., about 5.0 h·°F.·ft²·in/BTU for the extruded polystyrene material of the core membercompared to about 0.21 h·° F.·ft²·in/BTU for the grout material). In oneembodiment, the offset portion has an R-value of at least 1.0 h·°F.·ft²/BTU. In an exemplary embodiment, the offset portion 12 is about ⅜inches thick, with the offset portion having a section R-value of about2.1 h·° F.·ft²/BTU, compared to a section R-value of about 0.24 h·°F.·ft²/BTU for a comparable volume of grout material.

In forming an exemplary simulated brick, in accordance with an exemplaryaspect of the present application, an elongated block or sheet of thecore member material (e.g., extruded polystyrene, or other insulationboard) may be cut (e.g., hot wire cut) to form an elongated (e.g. about2 to about 20 feet long, preferably about 4 to about 8 feet long) coredefining the brick profile portion 11 and the offset portion 12, asshown. For ease of cutting, the junction between the outer surface 14 b′of the offset portion 12′ and the first lateral surface 13 a′ of thebrick profile portion 11′ may include a radius 18′ (e.g., a radius ofabout ⅛ inch), as shown in the exemplary simulated brick 10′ of FIG. 3.In other embodiments, the elongated shaped core may be extruded, molded,or otherwise formed without a cutting operation.

The mesh material is then adhered onto the lateral surfaces 13 a, 13 b,13 c and the outer surfaces 14 a, 14 b of the elongated core, forexample, by applying (e.g., wrapping, pressing) a self-adhesive side ofa mesh material sheet to the lateral and outer surfaces of the elongatedcore 20, for example, to hold the mesh material in place prior toapplication of the coating 40. The mesh material may be pre-cut to sizefor coverage of the elongated core, or trimmed after adhesion to removeany overhanging material.

A polymer modified cementitious basecoat material is prepared (e.g., bymixing) and is supplied, for example, in a hopper. The mesh-covered coreis pushed (manually or using an automated system) through an extrusioncoating machine to deposit or extrude (e.g., from a hopper above theextruding machine) the polymer modified cementitious basecoat materialover the mesh layer 30 on the lateral surfaces 13 a, 13 b, 13 c and theouter surfaces 14 a, 14 b of the core. The mesh material may be an openweave material, such that the basecoat material penetrates the meshlayer to adhere to the core material, which may further reinforceattachment of the mesh material to the core. In some embodiments, one ormore additional layers of basecoat material may be applied.

A finish material (e.g., an acrylic-based architectural finish) is mixedor otherwise prepared, and is supplied, for example, in a hopper. Oncethe basecoat layer 43 has cured and/or dried and (optionally) has beeninspected for imperfections, the coated core is pushed (manually orusing an automated system) through an extrusion coating machine todeposit or extrude (e.g., from a hopper above the extruding machine) thefinish material over the basecoat layer 43 on the lateral surfaces 13 a,13 b, 13 c and the outer surfaces 14 a, 14 b to form the finish layer46. Prior to fully curing and/or drying, the finish layer may be treated(e.g., rolled, pressed, broadcast of additional materials, etc.) toprovide a desired exterior texture or appearance.

Once the finish layer 46 has dried, the coated elongated core may be cutinto brick-sized lengths (e.g., between about 3 inches and about 12inches, or about 7⅝ inches) to form multiple, substantially identicalsimulated bricks 10. The resulting simulated bricks may then bepackaged, stored, and/or shipped for application to an exterior wall.

In accordance with various exemplary embodiments of the presentapplication, a method of applying an array of simulated brick claddingcomponents to an exterior wall is contemplated for forming an exteriorwall system. In an exemplary method, base surface portions of simulatedbricks (e.g., the simulated bricks described above and shown in FIGS.1-3, and/or simulated bricks constructed using the methods describedabove) are secured to an exterior wall substrate using a suitableadhesive layer, such as polyurethane foam, polyurethane constructionadhesive, acrylic based adhesive, or a polymer modified cementitiousmortar as described herein. Suitable substrates include, for example,concrete, masonry, brick, plywood, oriented strand board, cement board,glass mat face gypsum sheathing, insulated concrete forms (ICFs), andEIFS basecoat. In an exemplary wall system 1, as shown in FIG. 4, a wall2 (e.g., concrete, masonry, ICF, framed wall with sheathing) is coatedwith an EIFS cladding 3, which includes a fiberglass reinforced EIFSbasecoat 4. While the simulated bricks may be secured directly to, andin uniform planar contact with, the EIFS basecoat 4, in the illustratedembodiment, the adhesive layer includes a series of spaced apartadhesive strips 5 or other such spacers are provided between the EIFSbasecoat 4 and the base surface portions 16 of the simulated bricks 10,for example, to facilitate drainage of incidental water that may enterthe cavity behind the bricks. Similar strips 5 may likewise be providedbetween the EIFS cladding 3 and basecoat 4.

As shown in FIG. 4, the simulated bricks 10 are secured to the EIFSbasecoat wall surface in adjacent rows, with lateral end surfaces 13 cof the offset portions 12 of the simulated bricks of a first rowabutting the second lateral sides 13 b of the simulated bricks of asecond row, to define lateral gaps g1 between these lateral surfaces 13b, 13 c. The simulated bricks 10 in each row may likewise be spaced fromeach other by longitudinal gaps g2, for example by manual user placementof the adjacent simulated bricks to provide such gaps g2, or by use of alongitudinally extending offset portion (not shown), as described above.Once the adhesive sufficiently cures, the gaps g1, g2 may besubstantially filled by a grout or mortar material 6 applied between thebricks 10 and over the outer surfaces of the offset portions. Inaccordance with embodiments disclosed herein, the mortar or groutmaterial used between the exterior wall cladding bricks in the systemsdisclosed herein may comprise the same or similar polymer modifiedcementitious mortar material that is used as the basecoat. As analternative, an elastomeric sealant material may be used between thebricks. Preferably, the mortar/sealant imparts water resistance to thejoints between the exterior wall cladding bricks.

The present disclosure is also directed to exterior wall claddingsystems comprising the exterior wall claddings disclosed herein asapplied to an exterior wall or exterior wall system. An exemplary wallsystem of the present disclosure may include an offset-aligned, multiplerow array of simulated brick wall cladding components secured to anexterior wall surface by a mortar/grout material, with gaps between theadjacent simulated bricks filled by a mortar/grout material as shown inFIG. 4 and described above.

Unless otherwise indicated herein, all sub-embodiments and optionalembodiments are respective sub-embodiments and optional embodiments toall embodiments described herein. While the present application has beenillustrated by the description of embodiments thereof, and while theembodiments have been described in considerable detail, it is not theintention of the applicants to restrict or in any way limit the scope ofthe appended claims to such detail. Additional advantages andmodifications will readily appear to those skilled in the art.Therefore, the application, in its broader aspects, is not limited tothe specific details, the representative compositions or formulations,and illustrative examples shown and described. Accordingly, departuresmay be made from such details without departing from the spirit or scopeof the applicant's general disclosure herein.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art. In case of conflict, the present document, includingdefinitions, will control. Preferred methods and materials are describedbelow, although methods and materials similar or equivalent to thosedescribed herein may be used in practice or testing of the nutritionalcomposition. The materials, methods, and examples disclosed herein areillustrative only and not intended to be limiting.

The terms “comprise(s),” “include(s),” “having,” “has,” “can,”“contain(s),” and variants thereof, as used herein, are intended to beopen-ended transitional phrases, terms, or words that do not precludethe possibility of additional acts or structures. The singular forms“a,” “an” and “the” include plural references unless the context clearlydictates otherwise. The present disclosure also contemplates otherembodiments “comprising,” “consisting of” and “consisting essentiallyof,” the embodiments or elements presented herein, whether explicitlyset forth or not. Furthermore, to the extent that the term “or” isemployed (e.g., A or B) it is intended to mean “A or B or both.” Whenthe applicants intend to indicate “only A or B but not both” then theterm “only A or B but not both” will be employed. Thus, use of the term“or” herein is the inclusive, and not the exclusive use.

All percentages, parts, and ratios as used herein are by weight of thetotal product, unless specified otherwise. All ranges and parameters,including but not limited to percentages, parts, and ratios, disclosedherein are understood to encompass any and all sub-ranges assumed andsubsumed therein, and every number between the endpoints. For example, astated range of “1 to 10” should be considered to include any and allsub-ranges beginning with a minimum value of 1 or more and ending with amaximum value of 10 or less (e.g., 1 to 6.1, or 2.3 to 9.4), and to eachinteger (1, 2, 3, 4, 5, 6, 7, 8, 9, and 10) contained within the range.

All combinations of method or process steps as used herein can beperformed in any order, unless otherwise specified or clearly implied tothe contrary by the context in which the referenced combination is made.

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, circuits, devices and components, hardware,alternatives as to form, fit and function, and so on—may be describedherein, such descriptions are not intended to be a complete orexhaustive list of available alternative embodiments, whether presentlyknown or later developed. Those skilled in the art may readily adopt oneor more of the inventive aspects, concepts or features into additionalembodiments and uses within the scope of the present inventions even ifsuch embodiments are not expressly disclosed herein. Additionally, eventhough some features, concepts or aspects of the inventions may bedescribed herein as being a preferred arrangement or method, suchdescription is not intended to suggest that such feature is required ornecessary unless expressly so stated. Still further, exemplary orrepresentative values and ranges may be included to assist inunderstanding the present disclosure, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Moreover, whilevarious aspects, features and concepts may be expressly identifiedherein as being inventive or forming part of an invention, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificinvention. Descriptions of exemplary methods or processes are notlimited to inclusion of all steps as being required in all cases, nor isthe order that the steps are presented to be construed as required ornecessary unless expressly so stated.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicant torestrict or in any way limit the scope of the invention to such detail.Additional advantages and modifications will readily appear to thoseskilled in the art. For example, the specific locations of the componentconnections and interplacements can be modified. Therefore, theinvention, in its broader aspects, is not limited to the specificdetails, the representative apparatus, and illustrative examples shownand described. Accordingly, departures can be made from such detailswithout departing from the spirit or scope of the applicant's generalinventive concept.

We claim:
 1. A wall system comprising: a wall substrate including asubstantially planar exterior surface; and at least first and secondsimulated bricks, each comprising a brick profile portion having firstand second lateral sides extending to a planar outer surface to define afirst thickness, and an offset portion extending from the first lateralside of the brick profile portion to a lateral end surface and having anouter surface defining a second thickness smaller than the firstthickness, the brick profile portion and the offset portion togetherdefining a planar rectangular base surface extending from the secondlateral side of the brick profile portion to the lateral end surface ofthe offset portion; wherein the planar rectangular base surfaces of thefirst and second simulated bricks are adhered to the exterior surface ofthe wall substrate such that at least a portion of the lateral endsurface of the offset portion of the second simulated brick abuts thesecond lateral side of the brick profile portion of the first simulatedbrick; and wherein a grout material is adhered to the outer surface ofthe offset portion of the second simulated brick.
 2. The system of claim1, wherein the first and second simulated bricks are substantiallyidentical.
 3. The system of claim 1, wherein the first and secondsimulated bricks each comprise a polymeric core member, a mesh layeradhered to the core member, a basecoat layer covering an entirety of themesh layer, and a finish layer covering an entirety of the basecoatlayer, wherein the core member, the mesh layer, the basecoat layer, andthe finish layer together define the brick profile portion and theoffset portion.
 4. The system of claim 3, wherein the finish layer ofeach of the first and second simulated bricks defines the first andsecond lateral sides and the outer surface of the brick profile portionand the lateral end surface and the outer surface of the offset portionof the corresponding one of the first and second simulated bricks, andthe core member defines the base surface of the corresponding one of thefirst and second simulated bricks.
 5. The system of claim 3, wherein themesh layer, the basecoat layer, and the finish layer of each of thefirst and second simulated bricks together form a laminate having athickness of approximately ⅛ inch.
 6. The system of claim 3, wherein thecore member of each of the first and second simulated bricks comprisesat least one of polystyrene, extruded polystyrene, expanded polystyrene,polyisocyanurate, polyurethane, and foam glass.
 7. The system of claim3, wherein the mesh layer of each of the first and second simulatedbricks comprises at least one of fiberglass, polyester, polypropylene,carbon, and aramid.
 8. The system of claim 3, wherein the mesh layer ofeach of the first and second simulated bricks comprises a fire resistantmaterial.
 9. The system of claim 3, wherein the finish layer of each ofthe first and second simulated bricks comprises at least one of acrylic,vinyl acrylic, styrene acrylic, and vinyl acetate.
 10. The system ofclaim 3, wherein the core member of each of the first and secondsimulated bricks has a density between about 0.5 pcf and about 5 pcf.11. The system of claim 3, wherein the basecoat layer of each of thefirst and second simulated bricks comprises polymer-modified cement. 12.The system of claim 1, wherein the second thickness of each of the firstand second simulated bricks is between 5% and 70% of the first thicknessof the corresponding one of the first and second simulated bricks. 13.The system of claim 1, wherein the second thickness of each of the firstand second simulated bricks is between 35% and 60% of the firstthickness of the corresponding one of the first and second simulatedbricks.
 14. The system of claim 1, wherein the brick profile portion ofeach of the first and second simulated bricks has an R-value of at least2.0 h·° F.·ft²·in/BTU.
 15. The system of claim 1, wherein the offsetportion of each of the first and second simulated bricks has an R-valueof at least 1.0 h·° F.·ft²·in/BTU.
 16. The system of claim 1, whereinthe planar rectangular base surfaces of the first and second simulatedbricks are adhered to the exterior surface of the wall substrate by anadhesive layer comprising at least one of polyurethane foam,polyurethane construction adhesive, and acrylic based adhesive.
 17. Thesystem of claim 1, wherein the grout material comprises at least one ofType N cement mortar, Type S cement mortal, and elastomeric sealant. 18.The system of claim 1, wherein the planar rectangular base surfaces ofthe first and second simulated bricks are adhered to the exteriorsurface of the wall substrate by an adhesive layer, wherein the adhesivelayer and the grout material are the same material.
 19. The system ofclaim 1, wherein the grout material adhered to the outer surface of theoffset portion of the second simulated brick substantially fills a gapbetween the first lateral side of the brick profile portion of thesecond simulated brick and the second lateral side of the brick profileportion of the first simulated brick.
 20. A method of applying simulatedbricks to a wall surface, the method comprising: providing at leastfirst and second simulated bricks, each comprising a brick profileportion having first and second lateral sides extending to a planarouter surface to define a first thickness, and an offset portionextending from the first lateral side of the brick profile portion to alateral end surface and having an outer surface defining a secondthickness smaller than the first thickness, the brick profile portionand the offset portion together defining a planar rectangular basesurface extending from the second lateral side of the brick profileportion to the lateral end surface of the offset portion; applying anadhesive layer to the wall surface; adhering the base surface of thefirst simulated brick to the adhesive layer; adhering the base surfaceof the second simulated brick to the adhesive layer such that at least aportion of the lateral end surface of the offset portion of the secondsimulated brick abuts the second lateral side of the brick profileportion of the first simulated brick; and applying a grout material tothe outer surface of the offset portion of the second simulated brick.